Artificial leather and method for making the same

ABSTRACT

The present invention relates to an artificial leather and method for making the same. The artificial leather includes a polyester fiber substrate and a thermoplastic polyester elastomer (TPEE) resin layer. The polyester fiber substrate has a plurality of polyester fibers. The thermoplastic polyester elastomer (TPEE) resin layer is disposed adjacent to the polyester fiber substrate, and the material thereof is thermoplastic polyester elastomer (TPEE). Whereby, the material of the all layers of the artificial leather is polyester types, therefore, the whole artificial leather can be melted to recycle and reuse when disposing the artificial leather, so as to achieve the effect of environmental protection.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an artificial leather and a method for making the same, and in particular, to a polyester-series artificial leather and a method for making the same.

2. Description of the Related Art

In the conventional method for making an artificial leather, a nonwoven fabric is coated with a polyurethane (PU) and then is extruded, so that the PU infiltrates the nonwoven fabric. Finally, the nonwoven fabric passes through a coagulative water bath, allowing the Dimethyl Formamide (DMF) solvent in the PU to replaced with the water, so that the PU will be solidified, thereby producing an artificial leather. Defects of this method lie in that, a large amount of DMF solvent needs to be consumed, and a large amount of waste water is produced after the washing process. The recycling process of the waste water is also rather complicated. Moreover, in the artificial leather, the PU resin layer cannot be separated from the nonwoven fabric so that the leather cannot be recycled or reused because of the difference in materials. As a result, it will create a large amount of waste, and has a negative effect on the environment.

Therefore, it is necessary to provide a creative and progressive artificial leather and a method for making the same to solve the foregoing problems.

SUMMARY OF THE INVENTION

The present invention provides a method for making an artificial leather, including: (a) providing a Thermoplastic Polyester Elastomer (TPEE); (b) enabling the TPEE to form a molten TPEE; and (c) enabling the molten TPEE to form a TPEE resin layer, and then attaching the TPEE resin layer on a polyester fiber substrate by using a chilling roller, so as to form an artificial leather.

The present invention also provides a method for making an artificial leather, including: (a) providing a TPEE; (b) adding a foaming agent to the TPEE to form a first raw material, and then heating the first raw material, so that the first raw material forms a molten foamed TPEE, where the weight of the foaming agent is 1% to 10% of the weight of the TPEE; (c) heating a second raw material, so as to form a molten second material; (d) forming a bi-layer structure from the molten foamed TPEE and the second raw material, where the bi-layer structure has a foamed TPEE resin layer and a second raw material layer; and (e) attaching the bi-layer structure to a polyester fiber substrate, so as to form an artificial leather.

The present invention further provides an artificial leather, including a polyester fiber substrate and a foamed TPEE resin layer, wherein the polyester fiber substrate has a plurality of polyester fibers, the foamed TPEE resin layer is adjacent to the polyester fiber substrate, and the material thereof is TPEE.

In the present invention, the method for making the artificial leather does not require any solvent, and in comparison to the conventional process, this method does not produce any waste water, thereby protecting the environment. Additionally, the materials of all layers of the artificial leather are polyester types. Therefore, the method of disposal for the artificial leather is to entirely and directly melt the artificial leather for recycling and reuse, thereby protecting the environment, too.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described according to the appended drawings in which:

FIG. 1 is a schematic block diagram of an embodiment of a method of making an artificial leather in accordance with the present invention;

FIG. 2 is a schematic sectional view of an embodiment of an artificial leather according to the present invention;

FIG. 3 is a schematic block diagram of another embodiment of a method for making an artificial leather in accordance with the present invention;

FIG. 4 is a schematic sectional view of an embodiment of an artificial leather according to the present invention;

FIG. 5 is a schematic block diagram of another embodiment of a method for making an artificial leather in accordance with the present invention; and

FIG. 6 is a schematic sectional view of another embodiment of an artificial leather according to the present invention.

PREFERRED EMBODIMENT OF THE PRESENT INVENTION Embodiment 1

Referring to FIG. 1, a schematic block diagram of an embodiment of a method for making an artificial leather in accordance with the present invention is shown. First, the Thermoplastic Polyester Elastomer (TPEE) 10 is provided. In this embodiment, the TPEE 10 is AP007 (purchased from the Eastman Chemical Company), and is dried for 3 to 4 hours, so that the moisture content thereof is lower than 300 ppm, and a foaming agent 11 (for example, Hydrocerol, purchased from the Clariant Chemical Company) may be or may not be added, so as to form a first raw material 12.

Then the first raw material 12 is heated to form a molten TPEE 14. In this embodiment, the first raw material 12 is heated by an extruder 13 and the molten TPEE 14 is extruded by the extruder 13. The extruder 13 has a flow path (not shown), for the first raw material 12 to flow. Additionally, different temperatures are set at different positions of the flow path. For example, the flow path can be divided into five sections, and the five sections are set to be 200° C., 220° C., 240° C., 250° C., and 260° C., respectively.

Afterwards, film-forming the molten TPEE 14, so as to form a TPEE resin layer 16. In this embodiment, the flow path of the extruder 13 is connected with a T-die 15. Furthermore, film-forming is performed to the molten TPEE 14 by using the T-die 15, so as to form the TPEE resin layer 16. Then the TPEE resin layer 16 is attached to a polyester fiber substrate 17, so as to form an artificial leather 2. In this embodiment, the polyester fiber substrate 17 is formed from a plurality of polyester fibers, and the TPEE resin layer 16 and the polyester fiber substrate 17 are pressed by a chilling roller 18, so as to form the artificial leather 2. Preferably, the chilling roller 18 has a chilling wheel and a driven wheel. The chilling wheel contacts the TPEE resin layer 16 and the driven wheel contacts the polyester fiber substrate 17. The chilling wheel has texture on its surface, after the pressing process, the TPEE resin layer 16 will be transferred a texture on it, and the texture corresponds with the chilling wheel surface. However, in other embodiments, the TPEE resin layer 16 can be directly adhered to the polyester fiber substrate 17 by an adhesive, so as to form the artificial leather 2.

Referring to FIG. 2, a schematic sectional view of an embodiment of an artificial leather according to the present invention is shown. The artificial leather 2 includes a polyester fiber substrate 17 and a foamed or non-foamed TPEE resin layer 16. The polyester fiber substrate 17 has a plurality of polyester fibers. The TPEE resin layer 16 is adjacent to the polyester fiber substrate 17, and the material thereof is a TPEE. In this embodiment, the TPEE resin layer 16 is directly attached to and in contact with the polyester fiber substrate 17. Preferably, the TPEE resin layer 16 has texture on an upper surface. In other embodiments, the TPEE resin layer 16 is adhered to the polyester fiber substrate 17 by an adhesive.

In this embodiment, the thickness of the polyester fiber substrate 17 is 0.75 to 0.8 mm, and the thickness of the TPEE resin layer 16 is 0.1 to 0.15 mm. The softness of the artificial leather 2 is greater than 3.5 mm (BLC ST300 Softness Tester) and preferably greater than 4.5 mm.

In the present invention, the method for making the artificial leather 2 does not require any solvent, and in comparison to the conventional process, this method does not produce any waste water, thereby protecting the environment. Additionally, the materials of all layers of the artificial leather 2 are polyester types. Therefore, the method of disposal for the artificial leather 2 is to entirely and directly melt the artificial leather 2 for recycling and reuse, thereby protecting the environment, too.

Embodiment 2

Referring to FIG. 3, a schematic block diagram of another embodiment of a method for making an artificial leather in accordance with the present invention is shown. First, a TPEE 30 is provided. In this embodiment, the TPEE 30 is AP007 (purchased from the Eastman Chemical Company), and is dried for 3-4 hours, so that the moisture content thereof is lower than 300 ppm. Then, a foaming agent 31 (for example, Hydrocerol, purchased from the Clariant Chemical Company) is added to the TPEE 30, so as to form a first raw material 32. In this embodiment, the weight of the foaming agent 31 is 1% to 10%, and preferably, 2% to 4%, of the weight of the TPEE 30.

Next, the first raw material 32 is heated, so as to form a molten foamed TPEE 34. In this embodiment, the first raw material 32 is heated by a first extruder 33 and the molten foamed TPEE 34 is extruded by the first extruder 33. The extruder 33 has a first flow path (not shown), for the first raw material 32 to flow, and different temperatures are set at different positions of the first flow path. For example, the first flow path can be divided into five sections, and the five sections are set at 200° C., 220° C., 240° C., 250° C., and 260° C., respectively.

Meanwhile, a second raw material 35 is heated, so as to form a molten second raw material 37. In this embodiment, the second raw material 35 is a TPEE, and is not foamed. The second raw material (TPEE) 35 is heated by a second extruder 36, so as to form the molten second raw material (TPEE) 37. The second extruder 36 has a second flow path, for the second raw material 35 to flow.

Afterwards, the molten foamed TPEE 34 and the molten second raw material 37 are co-extruded at the same time, and then film-forming is performed, so as to form a bi-layer structure 39. In this embodiment, the first flow path of the first extruder 33 and the second flow path of the second extruder 36 are each connected with a multi-layer T-die 38. The molten foamed TPEE 34 and the molten second raw material (TPEE) 37 are co-extruded at the same time by using the T-die 38, and then film-forming is performed, so as to form the bi-layer structure 39. The bi-layer structure 39 has a foamed TPEE resin layer 16 and a second raw material layer 19 (a non-foamed TPEE resin layer, shown in FIG. 4). The porosity of the TPEE resin layer 16 is 30% to 80%, preferably, 50% to 70%.

Next, the bi-layer structure 39 is attached to a polyester fiber substrate 17, so as to form an artificial leather 2 a. In this embodiment, the polyester fiber substrate 17 is formed by a plurality of polyester fibers, and the bi-layer structure 39 and the polyester fiber substrate 17 are pressed by a chilling roller 18 to form the artificial leather 2 a, where the foamed TPEE resin layer 16 contacts the polyester fiber substrate 17. Preferably, the chilling roller 18 has a chilling wheel and a driven wheel. The chilling wheel is in contact with the second raw material 19 (non-foamed TPEE resin layer) and the driven wheel is in contact with the polyester fiber substrate 17. The chilling wheel has texture on its surface, and, after the pressing process, the second raw material layer 19 (non-foamed TPEE resin layer) has corresponding texture on a surface.

Referring to FIG. 4, a schematic sectional view of another embodiment of an artificial leather according to the present invention is shown. The artificial leather 2 a includes a polyester fiber substrate 17, a foamed TPEE resin layer 16, and a non-foamed TPEE resin layer 19. The polyester fiber substrate 17 has a plurality of polyester fibers. The foamed TPEE resin layer 16 is adjacent to the polyester fiber substrate 17, and the material thereof is a TPEE. In this embodiment, the porosity of the foamed TPEE resin layer 16 is 30% to 80%, and the diameter of a pore is in a micron order. Also, the foamed TPEE resin layer 16 contacts the polyester fiber substrate 17. The non-foamed TPEE resin layer 19 is adjacent to the foamed TPEE resin layer 16, and the material thereof is the TPEE. Preferably, the non-foamed TPEE resin layer 19 has texture on an upper surface.

In this embodiment, the thickness of the polyester fiber substrate 17 is 0.75 to 0.8 mm, the thickness of the foamed TPEE resin layer 16 is 0.1 to 0.15 mm. Also, the thickness of the non-foamed TPEE resin layer 19 is 0.1 to 0.15 mm, and the softness of the artificial leather 2 a is greater than 3.5 mm (BLC ST300 Softness Tester), and preferably greater than 4.5 mm.

Embodiment 3

Referring to FIG. 5, a schematic block diagram of another embodiment of a method for making an artificial leather in accordance with the present invention is shown. First, a TPEE 40 is provided. In this embodiment, the TPEE 40 is AP007 (purchased from the Eastman Chemical Company), and is dried for 3 to 4 hours, so that the moisture content thereof is lower than 300 ppm. Next, a foaming agent 41 (for example, Hydrocerol, purchased from the Clariant Chemical Company) is added to the TPEE 40, so as to form a first raw material 42. In this embodiment, the weight of the foaming agent 41 is 1% to 10%, preferably 2% to 4%, of the weight of the TPEE 40. Then, the first raw material 42 is heated, so as to form a molten foamed TPEE 44. In this embodiment, the first raw material 42 is heated by a first extruder 43 and the molten foamed TPEE 44 is extruded by the first extruder 43. The first raw material 42 flows along a first flow path (not shown) of the extruder 43. Additionally different temperatures are set at different positions along the first flow path. For example, the first flow path can be divided into five sections, and the five sections are set at 200° C., 220° C., 240° C., 250° C., and 260° C., respectively.

Meanwhile, a second raw material 45 is heated, so as to form a molten second raw material 47. In this embodiment, the second raw material 45 is a hotmelt adhesive, and is not foamed. The hotmelt adhesive can be, for example, a polyethylene terephthalate (PET) hotmelt adhesive (TOYOBO GM420-K01). The second raw material (hotmelt adhesive) 45 is heated by a second extruder 46, so as to form the molten second raw material (hotmelt adhesive) 47. The second raw material 45 flows along a second flow path of the second extruder 46.

Afterwards, film-forming is performed on the molten foamed TPEE 44 and the molten second raw material 47, so as to form a bi-layer structure 49. In this embodiment, the first flow path of the first extruder 43 and the second flow path of the second extruder 46 are each connected with a multi-layer T-die 48. The molten foamed TPEE 44 and the molten second raw material (hotmelt adhesive) 47 are co-extruded at the same time by the T-die 48, and then film-forming is performed, so as to form the bi-layer structure 49. The bi-layer structure 49 has a foamed TPEE resin layer 16 and a second raw material layer 51 (a hotmelt adhesive layer, shown in FIG. 6). The porosity of the TPEE resin layer 16 is 30% to 80%, preferably, 50% to 70%. Next, the bi-layer structure 49 is attached to a polyester fiber substrate 17 to form an artificial leather 2 b. In this embodiment, the polyester fiber substrate 17 is formed by a plurality of polyester fibers. The bi-layer structure 49 and the polyester fiber substrate 17 are thermally pressed in a hot pressing process 50, so as to form the artificial leather 2 b, where the second raw material layer 51 (hotmelt adhesive layer) is adhered the polyester fiber substrate 17.

Preferably, the bi-layer structure 49 is adhered to the polyester fiber substrate 17 after undergoing a rolling and pressing process. In the rolling and pressing process, a chilling roller is used to press the foamed TPEE resin layer 16 and the second raw material layer 51 (hotmelt adhesive layer). The chilling roller has a chilling wheel and a driven wheel, the chilling wheel is in contact with the foamed TPEE resin layer 16, and the driven wheel is in contact with the second raw material layer 51 (hotmelt adhesive layer). The chilling wheel has texture on its surface, and, after the pressing process, the TPEE resin layer 16 has corresponding texture on a corresponding surface.

Referring to FIG. 6, a schematic sectional view of another embodiment of an artificial leather according to the present invention is shown. The artificial leather 2 b includes a polyester fiber substrate 17, a hotmelt adhesive layer 51, and a foamed TPEE resin layer 16. The polyester fiber substrate 17 has a plurality of polyester fibers. The hotmelt adhesive layer 51 is located between the foamed TPEE resin layer 16 and the polyester fiber substrate 17. The foamed TPEE resin layer 16 is adhered to the polyester fiber substrate 17 by the hotmelt adhesive layer 51, that is, the hotmelt adhesive layer 51 is directly in contact with both the foamed TPEE resin layer 16 and the polyester fiber substrate 17. The material of the foamed TPEE resin layer 16 is a TPEE. In this embodiment, the porosity of the foamed TPEE resin layer 16 is 30% to 80%, and the diameter of a pore is in a micron order. Preferably, the foamed TPEE resin layer 16 has texture on an upper surface.

In this embodiment, the thickness of the polyester fiber substrate 17 is 0.75 to 0.8 mm, and the thickness of the hot glue layer 51 is 0.1 to 0.15 mm. The thickness of the foamed TPEE resin layer 16 is 0.1 to 0.15 mm, and the softness of the artificial leather 2 a is greater than 3.5 mm (BLC ST300 Softness Tester), preferably, greater than 4.5 mm.

The foregoing embodiments merely illustrate the principle and effects of the present invention, and are not intended to limit the present invention. Therefore, modifications and variations made by persons skilled in the art to the foregoing embodiments still do not depart from the spirit of the present invention. The scope of the claims of the present invention is subjected to the scope of the claims described in the following. 

What is claimed is:
 1. A method for making an artificial leather, comprising the following steps of: (a) providing a Thermoplastic Polyester Elastomer (TPEE); (b) enabling the TPEE to form a molten TPEE; and (c) enabling the molten TPEE to form a TPEE resin layer, and attaching the TPEE resin layer on a polyester fiber substrate by using a chilling roller to form an artificial leather.
 2. The method according to claim 1, wherein in step (b), the TPEE is heated by an extruder and the molten TPEE is extruded by the extruder, the extruder has a flow path for the TPEE to flow, and different temperatures are set at different positions of the flow path; in step (c), the TPEE resin layer is formed from the molten TPEE by using a T-die, and the flow path is connected with the T-die.
 3. The method according to claim 1, wherein in step (b), a foaming agent is further added into the TPEE for the TPEE to form the molten TPEE, and the weight of the foaming agent is 1% to 10% of the weight of the TPEE.
 4. A method for making an artificial leather, comprising the following steps of: (a) providing a Thermoplastic Polyester Elastomer (TPEE); (b) adding a foaming agent into the TPEE to form a first raw material, and heating the first raw material, so that the first raw material forms a molten foamed TPEE, wherein the weight of the foaming agent is 1% to 10% of the weight of the TPEE; (c) heating a second raw material to form a molten second raw material; (d) forming a bi-layer structure from the molten foamed TPEE and the second raw material , wherein the bi-layer structure has a foamed TPEE resin layer and a second raw material layer; and (e) attaching the bi-layer structure to a polyester fiber substrate to form an artificial leather.
 5. The method according to claim 4, wherein in step (b), the first raw material is heated by a first extruder and the molten foamed TPEE is extruded by the first extruder, the first raw material flows along a first flow path of the first extruder, and different temperatures are set at different positions of the first flow path; in step (c), the second raw material is heated by a second extruder, so as to form a molten second raw material, and the second raw material flows along a second flow path of the second extruder; in step (d), the molten foamed TPEE and the second raw material are co-extruded at the same time by using a multi-layer T-die, and then film-forming is performed, so as to form the bi-layer structure, wherein the first flow path and the second flow path are connected with the multi-layer T-die.
 6. The method according to claim 4, wherein in step (c), the second raw material is a TPEE; in step (d), the second raw material layer of the bi-layer structure is a non-foamed TPEE resin layer; in step (e), the bi-layer structure and the polyester fiber substrate are pressed by using a chilling roller, so as to form the artificial leather, wherein the foamed TPEE resin layer is in contact with the polyester fiber substrate.
 7. The method according to claim 4, wherein in step (c), the second raw material is a polyethylene terephthalate (PET) hotmelt adhesive; in step (d), the second raw material layer of the bi-layer structure is a PET hotmelt adhesive layer; in step (e), the bi-layer structure is attached to the polyester fiber substrate after being hot pressed, so as to form the artificial leather, wherein the PET hotmelt adhesive layer is adhered to the polyester fiber substrate.
 8. An artificial leather, comprising: a polyester fiber substrate, having a plurality of polyester fibers; and a foamed Thermoplastic Polyester Elastomer (TPEE) resin layer, adjacent to the polyester fiber substrate, wherein the material thereof is TPEE.
 9. The artificial leather according to claim 8, wherein the porosity of the foamed TPEE resin layer is in the range of 30% to 80%, and the foamed TPEE resin layer is adhered to the polyester fiber substrate.
 10. The artificial leather according to claim 8, further comprising a non-foamed TPEE resin layer, located on the foamed TPEE resin layer, wherein the material thereof is the TPEE, and the foamed TPEE resin layer is in contact with the polyester fiber substrate. 